ZF Rack and Pinion Power Steering Gears

for Passenger Cars and Light Commercial Vehicles

Millions of vehicles.
We can do the steering.
As vital for the vehicle as the engine
and the wheels, as important for
safety as the brake the steering
system is at the heart of every vehicle.
Whether it be a question of ope-
ration, safety or ride comfort, one
thing is clear the overall quality of
the vehicle also depends on the
quality of the steering. The require-
ments are clearly defined the
steering must be precise and free
from play, easy to operate and direct,
compact and light in weight.
Moreover, it should give the driver a
good "feel" of the road and favor the
return of the steered wheels into the
straight-ahead position. It has to
work shock-free, should require as
little maintenance as possible and, at
the same time, offer a maximum of
safety and comfort at both high and
low speeds.
When it comes to safety potential,
the power steering gear really comes
into its own at high speeds. Abrupt
steering corrections when maneu-
vering to avoid an obstacle, for
example are easy to master thanks
to the power assistance provided by
the servo mechanism. Also, the
hydraulic system will compensate for
the most part for sudden, one-sided
steering forces. The driver is able to
react to the surprise, keep the vehicle
on track and bring it to a halt. And all
this only requires a little extra effort
on the steering wheel.
2 Worth knowing
Steering the right way.
ZF Lenksysteme. Steering
toward the future.
As a joint venture of Robert Bosch
GmbH and ZF Friedrichshafen AG, ZF
Lenksysteme GmbH has produced
power steering systems for passenger
cars and commercial vehicles for
several decades. The products fulfill
every specified requirement. Take rack
and pinion and recirculating ball
power steering gears, for example.
These tried-and-tested steering
designs have been continually further
developed, protected by numerous
patents, and adapted to suit specific
vehicle requirements. The develop-
ment of the ZF compact power
steering gear involved the forging
of new paths both in valve
design and in production
processes.
One product of this approach
that really stands out is the ZF
Servotronic, an electronically
controlled and speed-sensitive
rack and pinion power steering
gear for passenger cars and light
commercial vehicles. It is char-
acterized by easy, comfortable
steering in parking operations and a
feeling of safe driving at increasing
speed as a result of more stiffness at
the steering wheel.
The ZF Active Steering sets new stan-
dards for implementingbothkinematic
steering assistance functions and
driving stabilizing functions.
It allows driver-
independent steering interventions
without the need to separate the
mechanical connection between
steering wheel and front axle. The
variable steering ratio coupled with
this clearly increases driving comfort
at low speeds.
Worth knowing 3
Installation schematic for a ZF compact
power steering gear with steering column,
engine-driven steering pump and oil
reservoir as well as pressure, suction and
return lines.
Servotronic

is a registered trademark
of ZF Lenksysteme GmbH.
Mechanical construction
The ZF rack and pinion power
steering gear basically comprises a
mechanical steering gear, the steering
valve and an integrated power
cylinder.
The rack (2) with the integrated
piston (3) is guided in wear-free plain
bearings within the power cylinder of
the housing (1). The pinion (4), which
runs in bearings in the valve area,
meshes with the rack teeth. The rack
is pressed against the pinion by
means of a spring-loaded yoke so
that the teeth always mesh without
play. The pinion is connected with the
valve rotor (5) through a torsion bar
(6). The rotary motion of the steering
wheel is transformed by the pinion
into an axial motion of the rack and
transferred to the steering arms by tie
rods (8).
The ZF rotary valve is a valve design
that has proved itself time and time
againin millions of applications. It is
used in order to control the
pressurized oil needed for power
assistance. This valve design mainly
comprises the valve rotor (5), which
has six control grooves on its surface
area, and the valve sleeve (7) securely
connected with the pinion (4).
ZF Rack and Pinion Power Steering Gears
ZF rack and pinion
power steering gear
with constant or
variable ratio, rotary
valve, integral housing
and end take-off.
4 Rack and pinion power steering gears
17 Radial groove
18 Pressure relief and flow
limiting valve
19 Steering pump
20 Oil reservoir
ZL Power cylinder, left
ZR Power cylinder, right
9 Feed oil radial groove
10 Feed oil control groove
11 Feed oil control edge
12 Axial groove
13 Return oil control groove
14 Return oil control edge
15 Return oil chamber
16 Radial groove
1 Housing
2 Rack
3 Piston
4 Pinion
5 Valve rotor
6 Torsion bar
7 Valve sleeve
8 Tie rod
1 3
15
14
9
11
12
13 17 10 16
ZR ZL
The valve bore of the valve sleeve has
axial grooves that are matched to the
control grooves of the valve rotor. The
centering of the valve rotor (neutral
position) is by means of a conven-
tional or a positive center feel torsion
bar (6) which is also the connecting
element between the valve rotor, the
pinion and the valve sleeve. The valve
rotor and pinion run in anti-friction
bearings to ensure the precision of
operation and the functional safety of
the steering valve even at high
pressures.
If a torque coming from the steering
wheel or from the steered road
wheels is transmitted to the valve
rotor or to the securely connected
pinion and valve sleeve, respectively, a
relative rotary motion influenced by
the torsion bar will occur between
the valve rotor and the valve
sleeve.
The valve rotor is thereby caused to
change its position in relation to the
valve sleeve bore surrounding it, so
that the relative positions of the
control grooves are changed, too.
Pressurized oil can now flow through
pipes to one of the two power
cylinder chambers (ZL or ZR) and
assists the axial movement of the rack
if the turning motion is initiated from
the steering wheel. If, however, the
axial movement of the rack is caused
by the road wheels, the steering valve
will, in spite of the steering wheel
being held, direct the pressurized oil
to that power cylinder chamber
which counteracts rack axial move-
ment. This braking effect dampens
road shocks. When the steering
wheel is released, the action of the
twisted torsion bar makes the control
grooves return to the neutral
position, and the same system
pressure will exist in both of the
power cylinder chambers.
ZF rack and pinion power steering gear,
type 7852, with end take-off.
Rotary valve in neutral position.
Rack and pinion power steering gears 5
2 4 8
6
5
7
16
9
17
15
20
19
18
Top figure:
ZF rack and pinion power steering gear,
type 7852, with end take-off.
Rotary valve in working position, steering
wheel turned clockwise.
6 Rack and pinion power steering gears
17 Radial groove
18 Pressure relief and flow
limiting valve
19 Steering pump
20 Oil reservoir
ZL Power cylinder, left
ZR Power cylinder, right
9 Feed oil radial groove
10 Feed oil control groove
11 Feed oil control edge
12 Axial groove
13 Return oil control groove
14 Return oil control edge
15 Return oil chamber
16 Radial groove
1 Housing
2 Rack
3 Piston
4 Pinion
5 Valve rotor
6 Torsion bar
7 Valve sleeve
8 Tie rod
1 2 4
8
3
15
6
5
7
16
9
17
15
20
19
18
14
9
11
12
13 17 10 16
ZR ZL
Basic hydraulic function of
the ZF rotary valve
The hydraulic fluid delivered by the
steering pump (19) flows through a
connnecting bore in the valve area,
via the feed oil radial groove (9) and
transverse bores in the valve sleeve
(7), onward to the three feed oil
control grooves (10) of the valve
rotor. In the valve neutral position
(fig. see page 4/5) the oil flows, over
the open feed oil control edges (11),
to all valve sleeve axial grooves (12)
and from there, over the open return
oil control edges (14), also to the
return oil control grooves (13) of the
valve rotor. From these grooves the oil
flows back, via connecting bores, to
the return oil chamber (15) and from
there to the oil reservoir (20). At the
same time, the radial grooves (16 and
17) of the valve body and their
associated pipes provide for a
connection between the right-hand
(ZR) and left-hand (ZL) power cylinder
chambers. When turning the steering
wheel clockwise (top fig.), the rack
with the integrated piston will move
to the right in the piston bore (to the
left in the installed position on the
vehicle) if the pinion is situated on
top. Due to the simultaneous rotation
of the valve rotor to the right, the
pressurized oil is directed, over the
further opened feed oil control edges
(11), to the three associated axial
grooves (12), via bores to the radial
groove (17), and, via a pipe, to the
Special equipment
The ZF rack and pinion power
steering gear can be fitted with a
number of equipment options in
order to adapt it in an optimum way
to the kinematic and motorization
conditions existing on the vehicle.
Variable ratio
Besides the constant ratio version, the
rack and pinion power steering gear
can also be made available with a
variable ratio. The rack teeth have
varying modules and pressure angles
so that, on the one hand, one can
ensure that, around center (i.e. in
straight-ahead driving), the steering
offers the response the driver is
accustomed to. On the other hand, as
the steering wheel turning angles (to
the right and to the left) become
greater, the ratio becomes lower and
the steering in consequence becomes
more direct. The difference between
the lowest and the highest ratio can
be as much as 35%. As a result,
values as unusually low as approx. 2
steering wheel turns from lock to lock
can be achieved.
The ZF variable ratio rack and pinion
power steering gear with its extra-
ordinary ease of handling is just as
suitable for mid-size saloons and light
commercial vehicles as for sporty
vehicles. It enables precise and rapid
steeering reactions at higher speeds
without running the risk of abruptly
pulling the steering wheel to the right
or left, and optimizes the handling of
the vehicle when maneuvering it into
or out of a parking space, when
turning it round in tight areas and
during extreme cornering.
Schematic ratio diagram for ZF rack and
pinion power steering gear with variable
ratio. One full turn of the steering wheel is
shown as 360 on this graph.
Rack travel (mm)
Turn of steering wheel
Steering wheel turning angle
Rack and pinion power steering gears 7
left-hand power cylinder chamber
(ZL), whereby the rack movement is
hydraulically assisted. An individually
adaptable pressure build-up is
achieved by the fact that the partially
or fully closed feed oil control edges
(11) restrict or prevent a connection
between the pressure oil inlet and the
other three axial grooves connected
to the radial groove (16). At the same
time, the pressure oil outlet toward
the pressurized axial grooves is
restricted or prevented, too, by the
closing return oil control edges (14).
The oil displaced by the piston (3)
from the right-hand power cylinder
chamber (ZR) first flows through a
pipe to the radial groove (16) and,
through transverse bores, to the
associated axial grooves and onward
to the return oil control grooves (13)
over the further opened return oil
control edges (14). From here, the
further return flow of the oil to the oil
reservoir (20) takes place via the
connnecting bores leading to the
return oil chamber (15). When the
steering wheel is turned counter-
clockwise, the operating sequence
will be analogous to the above.
4
0

20
d
2
Rack teeth around center Rack teeth in the end regions
d
1
Positive center feel torsion bar
The torsion bar is a most important
component in the steering valve.
Its design is decisive for steering
accuracy and steering feel at different
driving speeds. When the steering
valve is actuated, in other words,
when steering wheel motion begins,
the torsional force of the torsion bar
must be overcome. Without this
resistance the steering valve would be
too light and, in consequence, could
not be actuated in a precise and
controlled manner. In order to
optimize the steering valve in the
initial-hydraulic-assistance range and,
thereby, the steering characteristics,
in particular at higher speeds, ZF
Lenksysteme GmbH has developed
the positive center feel (PCF) torsion
bar on the basis of the conventional
torsion bar (top figure). Besides the
conventional rotary valves and rotary
spool valves, this PCF torsion bar is
used with the ZF Servotronic steering
valves.
The main elements of this com-
pact component are: a torsion bar,
a preloaded, torsion-proof metal
bellows spring, two sleeve-shaped
end pieces and a prism centering
device provided with balls. The
torsion bar is positively connect-
ed with the two end pieces.
The metal bellows spring,
which is arranged coaxially
with the torsion bar, is fas-
tened to one of the end pieces
at one end and to a centering
piece at the other end.
The prism centering device
consists of two centering pieces
each of which is provided with a
prism-shaped recess at its front end.
Cage-guided balls are arranged
between these recesses. The zero-
torsion position of the axially pre-
loaded metal bellows spring is
determined by the prism centering
device.
Right at the beginning of the torsion-
al motion, the metal bellows spring
produces a substantial additional
torsional resistance. As soon as the
prisms of the two centering pieces are
displaced to one another (starting
from a torsion angle of approx. 0.2),
the high metal bellows stiffness is no
longer present, and torsional rigidity
takes a shape similar to the charac-
teristic of the standard torsion bar.
8 Rack and pinion power steering gears
Fitment of the PCF torsion bar to the
ZF rotary valve.
Characteristics of a conventional
and a PCF torsion bar.
Nominal characteristic curve
This is a curve characteristic that
covers a very narrow tolerance band.
Conically formed control grooves
and control edges on the valve rotor
and the valve sleeve, coupled with
controlled assembly technique, allow
optimum configuration of the valve
characteristic curve in line with
vehicle manufacturer specifications.
Hydraulic steering limiter
There are functional, economical
and environmental advantages in
integrating a hydraulic steering
limiter into rack and pinion power
steering gears. A chassis with
sufficient self-aligning properties is,
however, a prerequisite for this.
Specially developed connecting cross
sections in the cylinder bore enable
an overflowing of the oil from
the cylinder chamber under high
pressure to the return oil chamber
separated from it by the piston, just
before the end of the stroke. The
pressure drop at the lock stop
resulting from this protects the
steering pump and the mechanical
parts of the steering gear from
excessive loads. A power assistance
heavily reduced by the pressure drop
causes an increase of the steering
wheel input torque and, thus,
informs the vehicle driver that
maximum wheel lock is imminent.
As the hydraulic steering limiter
reduces the power requirement of
the steering pump, the engine idling
speed can be set at a lower value,
thus saving a considerable amount
of fuel which, in turn, protects the
environment.
Steering damping
The main reason for increased levels
of steering comfort is the fact that
shocks caused by the road and the
chassis cannot be felt on the steering
wheel. In particular cases, additional
technical solutions can be adopted,
such as fixing the steering gear by
rubber mounts. But it is also possible
to use valve and orifice systems
(variable orifices) which are inte-
grated into the hydraulic system and
act as dampers.
Full-lock damping
If required, ZF rack and pinion power
steering gears can be fitted with
flexible plastic components on
the stroke limiters. The damping
effect in front of the metallic stop
(full lock) combats unwanted noise
at maximum wheel lock.
Rack and pinion power steering gears 9
Mechanical construction
The ZF compact power steeering gear
is based on a modular design, mainly
consisting of three modules a
mechanical steering gear, a steering
valve and a power cylinder.
The light metal housing (1) and the
form-fitted cylinder tube (2) form the
main body for locating the
mechanical ratio system and the
power cylinder. The rack (3) with the
integrated piston (4) is guided in
wear-free plain bearings. The pinion
(5), which runs in bearings in the
valve area, meshes with the rack
teeth. The rack is pressed against the
pinion by means of a spring-loaded
yoke so that the teeth always mesh
without play. A longitudinal bore in
the rack guarantees air compensation
between the two bellows chambers.
This bore is manufactured using a
special forming technique. The pinion
is connected with the valve body (7)
through a torsion bar (6). The rotary
motion of the steering wheel is
transformed by the pinion into an
axial motion of the rack. This motion
is transferred to the steering arms by
tie rods (9).
The ZF compact rotary valve (K-valve)
manufactured using a high
proportion of extremely precise and
economical production technology
is used in order to control the
pressurized oil needed for power
assistance. This valve design mainly
comprises the valve body (7), which
has eight control grooves in the valve
bore, and a control bush (8) securely
connected with the pinion (5). The
surface area of the control bush has
eight axial grooves that are matched
to the control grooves in the
valve bore.
ZF Compact Power Steering Gears
10 Compact power steering gears
ZF compact power steering
gear, type 7891, with
compact rotary valve,
pressed-on cylinder tube and
end take-off.
17 Radial groove
18 Radial groove
19 Pressure relief and flow
limiting valve
20 Steering pump
21 Oil reservoir
ZL Power cylinder, left
ZR Power cylinder, right
9 Tie rod
10 Feed oil radial groove
11 Feed oil control groove
12 Feed oil control edge
13 Axial groove
14 Return oil control groove
15 Return oil control edge
16 Return oil chamber
1 Housing
2 Cylinder tube
3 Rack
4 Piston
5 Pinion
6 Torsion bar
7 Valve body
8 Control bush
2 4
16 1
14
13
10
11
15 18 12 17
ZR ZL
The centering of the valve body
(neutral position) is by means of a
conventional or a positive center feel
torsion bar (6) which is also the
connecting element between the valve
body, the pinion and the control bush.
The valve body and pinion run in anti-
friction bearings to ensure the
precision of operation and the
functional safety of the steering valve,
even at high pressures.
If a torque coming from the steering
wheel or from the steered road
wheels is transmitted to the valve
body or to the securely connected
pinion and control bush, a relative
rotary motion influenced by
the torsion bar will occur
between the valve
body and the con-
trol bush.
The valve body is thereby caused to
change its position in relation to the
control bush inside it, so that the
relative positions of the control
grooves are changed, too. Pressurized
oil can now flow through pipes to
one of the two power cylinder
chambers (ZL or ZR) and assists the
axial movement of the rack if the
turning motion is initiated from the
steering wheel. If, on the contrary,
the axial movement of the rack is
caused by the road wheels, the
steering valve will, in spite of the
steering wheel being held, direct the
pressure oil to that power cylinder
chamber which counteracts the axial
motion of the rack. This braking
effect dampens road impacts.
When the steering wheel is released,
the action of the torsion bar makes
the control grooves return to the
neutral position, and the same system
pressure will exist in both of the
power cylinder chambers.
Compact power steering gears 11
ZF compact power steering gear, type 7891,
with end take-off.
Compact rotary valve in neutral position.
3 1 5
9
6
7
16
8
17
10
18
21
20
19
4
3
0
1
Compact power steering gears 12
Top figure:
ZF compact power steering gear, type 7891,
with end take-off.
Compact rotary valve in working position,
steering wheel turned clockwise.
The hydraulic fluid delivered by the
steering pump (20) flows through a
connecting bore in the valve area, via
the feed oil radial groove (10) and
transverse bores in the valve body (7),
onward to the four feed oil control
grooves (11) of the control bush (8).
In the valve neutral position (fig.
pages 10/11) the oil flows over the
open feed oil control edges (12) to all
valve body axial grooves (13) and
onward, over the open return oil
control edges (15), also to the return
oil control grooves (14) of the control
bush. From these grooves, the oil
flows back via bores to the return oil
chamber (16) and from there, via the
hose, to the oil reservoir (21). At the
same time, the radial grooves (17 and
18) of the valve body and their
associated pipes provide for a
connection between the right-hand
(ZR) and left-hand (ZL) power cylinder
chambers.
When turning the steering wheel
clockwise (top fig.), the rack (3) with
the integrated piston (4) will move to
the right in the cylinder tube (2), (to
the left in the installed position on the
vehicle), if the pinion (5) is situated on
top. Due to the simultaneous rotation
of the valve body to the right, the
pressurized oil is directed, over the
further opened feed oil control edges
(12), to the four associated axial
grooves (13), via bores to the radial
17 Radial groove
18 Radial groove
19 Pressure relief and flow
limiting valve
20 Steering pump
21 Oil reservoir
ZL Power cylinder, left
ZR power cylinder, right
9 Tie rod
10 Feed oil radial groove
11 Feed oil control groove
12 Feed oil control edge
13 Axial groove
14 Return oil control groove
15 Return oil control edge
16 Return oil chamber
1 Housing
2 Cylinder tube
3 Rack
4 Piston
5 Pinion
6 Torsion bar
7 Valve body
8 Control bush
2 3 1
5 9
4
16
6
7
16
8
17
10
18
21
20
19
14
13
10
11
15 18 12 17
ZR ZL
Basic hydraulic
function of the ZF compact
rotary valve
groove (18) and, via a pipe, to the
left-hand power cylinder chamber
(ZL), whereby the rack movement is
hydraulically assisted.
An individually adaptable pressure
build-up is achieved by the fact that
the partially or fully closed feed oil
control edges (12) restrict or prevent
a connection between the pressure
oil inlet and the other four axial
grooves (13) connected to the radial
groove (17). At the same time, the
pressure oil outlet toward the
pressurized axial grooves is restriced
or prevented, too, by the closing
return oil control edges (15). The oil
displaced by the piston (4) from the
right-hand power cylinder chamber
(ZR) first flows through a pipe to the
radial groove (17) and, through
transverse bores, to the associated
axial grooves and onward, over the
further opened return oil control
edges (15), to the return oil control
grooves (14). From here, the further
return flow of the oil to the oil
reservoir (21) takes place via the
connecting bores leading to the
return oil chamber (16). When the
steering wheel is turned counter-
clockwise, the operating sequence
will be analogous to the above.
Special equipment
Like the other power steering gears
made by ZF Lenksysteme GmbH, the
ZF compact power steering gear can
also be fitted with a number of
equipment options in order to adapt
it in an optimum way to the different
vehicle kinematic and motorization
conditions. In addition to the design
features described on pages 7 to 9,
the steering gear can be optionally
fitted with three types of valve
configuration. It is the modular
design that makes this possible. The
compact rotary valve, for example, is
used when space limitations exist,
and the standard rotary valve is used
for relatively large oil flows. The
Servotronic rotary valve with speed-
sensitive control is used where best
possible steering comfort is to be
achieved.
Schematic representation of the ZF
compact power steering gear with
various valve configurations.
1 Compact rotary valve
2 Standard rotary valve
3 Servotronic rotary valve
1 2 3
Compact power steering gears 13
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A Joint Venture of
Robert Bosch GmbH and
ZF Friedrichshafen AG
[Steering the right way]
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ZF Lenksysteme GmbH:
the systems partner
ZF Lenksysteme GmbH is one of the
largest independent manufacturers of
power steering systems for passenger
cars and commercial vehicles. Re-
nowned automotive manufacturers
from all over the world value us as a
creative and efficient systems partner
for the development of new and inno-
vative solutions.
As a joint venture of Robert Bosch
GmbH and ZF Friedrichshafen AG,
ZF Lenksysteme GmbH offers its cu-
stomers a unique source of expertise
when it comes to integrating a wide
range of top technologies in modules,
system modules or entire chassis
systems.
The benefits for the manufacturer are
clear to see: even shorter development
times and optimized production pro-
cesses with quality standards which
just get better and better.
ZF Lenksysteme GmbH
Richard-Bullinger-Strasse 77
73527 Schwbisch Gmnd
Germany
Phone: +49 (0)71 71 / 31-0
Telefax: +49 (0)71 71 / 31-32 22
www.zf-lenksysteme.com